Die Cut Packaging

Die cut packaging to enhance the unboxing user experience

The die cut process enables us to create more complicated, detailed and custom cardboard packaging. Die cutting tools ensure a level of consistency across the production process and achieve a high-quality finish.

What is Die-Cut Packaging?

Die-cutting is a manufacturing process that uses a specialised tool, known as a die, to cut a specific shape out of a material like corrugated cardboard. Think of it like a cookie-cutter for boxes. This technique allows for the creation of intricate and precise designs that standard box-making methods cannot achieve. The process starts with a digital design, or dieline, which is then used to create the physical die. This precision ensures that every cardboard box is identical, providing consistent quality for your packaging solutions.

The Manor Packaging design team have been designing die cut corrugated box solutions for over 35 years and have evolved in line with new technologies to have the knowledge and experience to help you achieve more from your packaging.  

The in-house design team’s expertise in print and structural engineering means that they can use CAD drawing techniques to create millimetre precise boxes and inners to hold and protect your product. It’s these correctly packaged and protected goods that give peace of mind when shipping, and eliminate damaged deliveries during transit.

The Manor Packaging team always structurally design pack solutions to be materially efficient. By not using excess materials this helps you save money, and is also more sustainable for the environment too.

It doesn’t just have to be practical either, the team will work with you to develop the most visually appealing look and feel either using existing brand guidelines or from a product and brief. We can incorporate your logo and branding to create custom printed boxes that stand out.

The Benefits of Custom Die-Cut Boxes

• Precision Protection: Custom-engineered die-cut inserts and boxes are designed to the exact specification of your product. This snug fit holds items securely, eliminating movement and the need for excessive void fill, which is crucial for protecting valuable or delicate goods.
• Enhanced Unboxing Experience: First impressions matter. A well-designed, easy-to-assemble die-cut box enhances the customer experience, making your brand more memorable.
• Sustainability: By designing to the exact dimension required, we minimise material waste. Our precision die-cut inserts are a durable and fully recyclable alternative to plastic vacuum-formed trays.
• Versatility and Functionality: From sturdy postal boxes to intricate display cartons, the versatility of die-cutting is unmatched. We can create boxes with self-locking flaps, crash-lock bases, or specific lid designs to suit any need.

Our Design and Prototyping Process

Creating the perfect template for your packaging is a collaborative process. We can work from a PDF or DXF file, or our team can create a custom dieline for you.

1. Consultation: We discuss your product, shipping needs, and brand requirements.
2. Digital Design: Our structural designers create a 2D dieline and a 3D mockup to visualise the final product.
3. Prototyping: We produce a physical sample for you to test and approve before committing to a full production run.

Popular Die-Cut Box Styles

While the customisation options are nearly limitless, one of the most popular styles is the FEFCO 0427. This robust mailer box style features a hinged lid and interlocking flaps or tabs that fold to create a durable, easy-to-assemble carton. The 0427 style is perfect for ecommerce shipments and subscription boxes, offering a secure and professional packaging solution.

Applications Across Industries

The precision engineering of die-cut packaging makes it suitable for a wide range of products and industries:

• Ecommerce & Retail: Used extensively for postal boxes, gift boxes, and packaging for beauty products, luxury confectionery, and more.
• Advanced Manufacturing & Engineering: We create heavy-duty pallet packaging with custom die-cut inserts to protect precision components, aerospace assemblies, and medical equipment from shock and vibration.
• High-Performance Motorsport: Our team designs robust transit cases with precision inserts to cradle individual components like carbon fibre parts and sensitive electronic control units.